U.S. patent application number 15/595547 was filed with the patent office on 2017-08-31 for system and method of preventing flow blocking when using an automated pig launcher.
The applicant listed for this patent is TDW Delaware, Inc.. Invention is credited to Troy D. Geren, Jeffrey C. Hailey, Tarek Kandalaft, William C. Keenan, Lee R. Shouse, Jr..
Application Number | 20170246667 15/595547 |
Document ID | / |
Family ID | 58671255 |
Filed Date | 2017-08-31 |
United States Patent
Application |
20170246667 |
Kind Code |
A1 |
Hailey; Jeffrey C. ; et
al. |
August 31, 2017 |
System and Method Of Preventing Flow Blocking When Using An
Automated Pig Launcher
Abstract
A flow assurance system and method includes procedures to query
current valve states and determine the likely effect of new valve
states on product flow when using an automated pig launcher. The
system and method allows for modulating the mainline bypass valve,
kicker valve, and isolation valve between fully opened and fully
closed states; prevents flow blocking of the pipeline during this
modulation; enables new and different, as well as a broader range
of, pig launching options for an automatic pig launcher; and
integrates with existing automatic pig launchers.
Inventors: |
Hailey; Jeffrey C.; (Tulsa,
OK) ; Shouse, Jr.; Lee R.; (Chelsea, OK) ;
Keenan; William C.; (Broken Arrow, OK) ; Geren; Troy
D.; (Tulsa, OK) ; Kandalaft; Tarek; (Tulsa,
OK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TDW Delaware, Inc. |
Wilmington |
DE |
US |
|
|
Family ID: |
58671255 |
Appl. No.: |
15/595547 |
Filed: |
May 15, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14989442 |
Jan 6, 2016 |
9651190 |
|
|
15595547 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01L 19/0092 20130101;
B08B 9/055 20130101; B08B 9/0325 20130101; F16L 55/26 20130101;
F16L 55/46 20130101; F16K 17/003 20130101; F16L 55/38 20130101 |
International
Class: |
B08B 9/032 20060101
B08B009/032; F16L 55/46 20060101 F16L055/46; F16K 17/00 20060101
F16K017/00 |
Claims
1. A method of enabling a product flow system of a pipeline pig
launcher to launch a pipeline pig into a mainline, the method
comprising: determining, using indicator data from a mainline
bypass valve indicator, a kicker valve indicator, and an isolation
valve indicator, a current state of valves, the current state being
in a range of fully opened to fully closed; sending a request over
a network to a microprocessor in communication with valve
controllers to change the current state of one or more of the
valves to a new state, the new state being different than the
current state and in a range of fully opened to fully closed;
determining, using the microprocessor and the current state of
valves left unchanged and the new state of valves to be changed, an
effect on product flow, the effect being one of increasing the
product flow or decreasing the product flow; the microprocessor
allowing the request if the product flow associated with the valves
left unchanged is outside the predetermined range; the
microprocessor denying the request if the product flow associated
with the valves left unchanged is within a predetermined range;
wherein the microprocessor includes a set of computer executable
instructions stored on non-transitory computer readable medium.
2. A method according to claim 1 wherein the request is denied if
at least one of the kicker valve and the isolation valve current
state is closed and the requested new state of the mainline bypass
valve is closed.
3. A method according to claim 1 further comprising: querying over
the network pressure indicators located upstream and downstream of
a mainline bypass valve; calculating, using the microprocessor and
pressure data from the pressure indicators, a differential pressure
across the mainline bypass valve; and comparing, using the
microprocessor the differential pressure to a predetermined
differential pressure.
4. A method according to claim 3 further comprising stopping
modulation of a valve before it reaches the new state if the
differential pressure is not within a predetermined range.
5. A method according to claim 4 further comprising reversing
modulation of the stopped valve back to its last current state.
6. A method according to claim 1 further comprising verifying a
current state of the valves prior to the sending a request.
7. A method according to claim 1 further comprising verifying the
new state of the one or more valves after allowing the request.
8. A method according to claim 1 further comprising querying said
valve indicators over the network.
9. A method according to claim 1 wherein the network is an internal
network, an external network, or a combination of an internal and
an external network.
10. A method of enabling a product flow system of a pipeline pig
launcher to launch a pipeline pig into a mainline, the method
comprising, the automated pig launcher including a microprocessor,
valve indicators, and valve controllers in network communication
with one another, the method comprising: querying over the network
a current state of valves as indicated by the valve indicators;
sending a request over the network to one or more of the valve
controllers to change a current state of one or more valves to a
new state, the new state being different than a current state and
in a range of fully opened to fully closed; determining, using the
microprocessor and a current state of valves left unchanged and the
new state of valves to be changed, an effect on product flow, the
effect being one of increasing the product flow or decreasing the
product flow; the microprocessor allowing the request if the
product flow associated with the valves left unchanged is outside
the predetermined range; the microprocessor denying the request if
the product flow associated with the valves left unchanged is
within a predetermined range; wherein the microprocessor includes a
set of computer executable instructions stored on non-transitory
computer readable medium.
11. A method according to claim 10 wherein the request is denied if
at least one of a kicker valve and an isolation valve current state
is closed and the requested new state of a mainline bypass valve is
closed.
12. A method according to claim 10 further comprising: querying
over the network pressure indicators located upstream and
downstream of a mainline bypass valve; calculating, using the
microprocessor and pressure data from the pressure indicators, a
differential pressure across the mainline bypass valve; and
comparing, using the microprocessor, the differential pressure to a
predetermined differential pressure.
13. A method according to claim 12 further comprising sending a
command over the network to stop modulation of a valve before it
reaches the new state if the differential pressure is not within a
predetermined range.
14. A method according to claim 13 further comprising sending a
command over the network to reverse modulation of the stopped valve
back to its last current state.
15. A method according to claim 10 further comprising querying over
the network a current state of the valves prior to the sending a
request.
16. A method according to claim 10 further comprising verifying the
new state of the one or more valves after allowing the request.
17. A method according to claim 10 wherein the network is an
internal network, an external network, or a combination of an
internal and an external network.
18. A method of enabling a product flow system of a pipeline pig
launcher to launch a pipeline pig into a mainline, the automated
pig launcher including a microprocessor, valve indicators, and
valve controllers in network communication with one another, the
method comprising: determining, using the microprocessor and a
current state of valves left unchanged and a new state of valves to
be changed, an effect on product flow of a request to change one or
more valves to a new state, the effect being one of increasing the
product flow or decreasing the product flow; the microprocessor
allowing a request to change a valve to the new state if the
product flow associated with the valves left unchanged is outside
the predetermined range; and the microprocessor denying the request
if the product flow associated with the valves left unchanged is
within a predetermined range; wherein the microprocessor includes a
set of computer executable instructions stored on non-transitory
computer readable medium.
19. A method according to claim 18 further comprising: querying
over the network a current state of valves as indicated by the
valve indicators; and sending over the network the request to
change one or more valves to a new state using the valve
controllers.
20. A method according to claim 18 further comprising: querying
over the network pressure indicators located upstream and
downstream of a mainline bypass valve; calculating, using the
microprocessor and pressure data from the pressure indicators, a
differential pressure across the mainline bypass valve; and
comparing, using the microprocessor, the differential pressure to a
predetermined differential pressure.
21. A method according to claim 20 further comprising sending a
command over the network to stop modulation of a valve before it
reaches the new state if the differential pressure is not within a
predetermined range.
22. A method according to claim 21 further comprising sending a
command over the network to reverse modulation of the stopped valve
back to its last current state.
23. A method according to claim 18 further comprising verifying the
new state of the one or more valves after the modulating.
24. A method according to claim 18 wherein the network is an
internal network, an external network, or a combination of an
internal and an external network.
Description
CROSS-REFERENCE To PENDING APPLICATIONS
[0001] This application is a continuation application of U.S.
patent application Ser. No. 14/989,442, filed Jan. 6, 2016, the
contents of which are hereby incorporated by reference in their
entirety.
BACKGROUND
[0002] This disclosure relates to launchers used to launch a
pipeline pig into a pipeline system. More specifically, the
invention relates to systems and methods of preventing flow
blocking when launching a pig using an automated pig launcher.
[0003] Pipeline pigs perform various pipeline maintenance, cleaning
and inspection operations while the pipeline continues to operate
under pressure and transport product. The pig is introduced into
the pipeline by way of a trap (the "pig launcher") connected to the
pipeline. Once the pig is placed inside the launcher, the closure
door of the launcher is closed and pipeline flow is used to push
the pig into and through the pipeline. The pig continues to travel
through the pipeline until the pig reaches a receiving trap (the
"pig catcher").
[0004] Referring to FIG. 1, a prior art pig launching system uses
gravity to launch a pig into a main pipeline. Pipeline product is
diverted into and flows through the launcher when the kicker and
isolation valves are opened and the mainline bypass valve is
closed,
[0005] Pig launching and receiving systems vary from one to another
depending on specific purpose and pipeline product. Variations
include such things as placement of valves, length of the launch
tube or barrel, type of closure door, and the means to move a pig
into the reduced cross-section area of the barrel (e.g. gravity,
screws).
[0006] Regardless of those variations, all launchers and receiver
include the barrel which holds one or more pigs, a large branch
connection which connects the barrel to the pipeline system, and a
set of valves that divert and control flow through and to the
launcher (see e.g. FIG. 1). The set of valves typically includes
the mainline bypass valve, mainline trap or isolation valve, and
trap kicker or kicker valve. When ready to launch a pig into the
pipeline system, a Tee section diverts pipeline fluid flow into the
end of the barrel, behind one or more of the pigs positioned in the
barrel.
[0007] In order to launch itself properly into the pipeline, the
pig must experience an adequate pressure differential across the
pig body. Gravity assistance can be used to move the pig into a
position to better accomplish this. Referring to FIG. 1, a prior
art pig launching system uses gravity to launch a pig into a main
pipeline. Pipeline product is diverted into and flows through the
launcher when the kicker and isolation valves are opened and the
mainline bypass valve is closed,
[0008] The ability to control bypass flow through the pig body,
therefore, is critical to providing sufficient acceleration of the
pig during its launch into the pipeline and controlling the speed
of the pig as it travels through the pipeline. In many cases--such
as those where minimal flow is available to push the pig out of the
launcher and into the pipeline--it is desirable to have minimum to
no bypass flow through the pig during the initial launch phase,
that is, up until the time at which the pig passes the isolation
valve.
[0009] U.S. Pat. No. 4,135,949 to Reese discloses monitoring the
operating condition of a pig launcher to prevent opening of the
launcher closure when there is a pressure in the launcher and to
prevent flow into the launcher when the launcher closure is not in
place. For example, the override maintaining the isolation valve in
a closed position cannot be removed until the pressure in the
barrel reaches a set point of about 1/2 to 1 psig.
[0010] Fully automated pig launchers have the potential to launch
pigs in ways that manual and semi-automated pig launchers could
not. For example, a fully automated system could modulate the
mainline bypass valve to create differential pressure sufficient to
launch a pig without the use of gravity assistance. However, this
modulation could potentially block product flow in the pipeline by
closing or partially closing the mainline bypass valve when the
kicker or isolation valves are closed or partially closed.
Therefore, a need exists for a system and method to prevent this
flow blocking and assure adequate flow of pipeline product.
SUMMARY
[0011] A flow assurance system and method of launching a pipeline
pig involves the following components and steps, with the steps of
the flow assurance module being executed by a set of computer
executable instructions stored on non-transitory computer readable
medium and executed by a microprocessor. The requests or commands
to query valve states, change or stop changes to valve states, and
to reverse valve states can occur over a network in communication
with the valve controllers and valve- and pressure indicators. The
steps include:
[0012] querying a mainline bypass valve indicator, a kicker valve
indicator, and an isolation valve indicator;
[0013] determining, using indicator data from the valve indicators,
a current state of each of the valves, the current state being in a
range of fully opened to fully closed;
[0014] sending a request to change the current state of one or more
of the valves to a new state, the new state being different than
the current state and in a range of fully opened to fully
closed;
[0015] determining, using the current state of valves left
unchanged and the new state of valves to be changed, an effect on
product flow in a mainline, the effect ranging one an increased,
decreased, or unchanged product flow;
[0016] denying the request if the effect is undesirable; and
[0017] modulating the one or more valves to the new state if the
effect is desirable (e.g., at least one of the kicker valve and the
isolation valve current state is closed and the requested new state
of the mainline bypass valve is closed).
The current state of the valves is verified prior to the sending
request step and after the modulating step.
[0018] The method also can include the steps of querying pressure
indicators located upstream and downstream of the mainline bypass
valve; calculating, using the pressure data from the pressure
indicators, a differential pressure across the mainline bypass
valve; and comparing the differential pressure to a predetermined
differential pressure. Modulation of a valve can be stopped before
it reaches the new state if the differential pressure is not within
a predetermined range. The modulation can then be reversed to bring
the stopped valve back to its last known current state.
[0019] Objectives are to provide flow assurance when using an
automated pig launcher and modulating the mainline bypass valve;
prevent flow blocking of the pipeline during this modulation;
enable new and different, as well as a broader range of, pig
launching options for an automatic pig launcher; and provide a flow
assurance system and method that can integrate with existing
automatic pig launchers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic of a prior art gravity assisted pig
launching system and its associated valves.
[0021] FIG. 2 is a schematic of an embodiment of a pig launching
system and its associated valves and sensors.
[0022] FIG. 3 is a schematic of an embodiment of a control system
used in connection with the pig launcher of FIG. 2 to prevent flow
blocking of the pipeline.
[0023] FIG. 4 is a flow diagram of an embodiment of a valve
monitoring and flow assurance process.
[0024] FIG. 5 is a flow diagram of an embodiment of the error
procedure for the valve monitoring and flow assurance process of
FIG. 4.
ELEMENTS AND NUMBERING USED IN THE DRAWINGS AND DETAILED
DESCRIPTION
[0025] 10 Automated pig launcher
[0026] 11 Launcher barrel
[0027] 13 Mainline bypass
[0028] 15 Mainline
[0029] 17 Tee Section
[0030] 18 Retractable pin or launch pin
[0031] 19 Upstream pressure indicator
[0032] 21 Mainline bypass valve
[0033] 23 Mainline bypass valve indicator
[0034] 25 Kicker valve
[0035] 27 Kicker valve indicator
[0036] 29 Isolation valve
[0037] 31 Isolation valve indicator
[0038] 33 Downstream pressure indicator
[0039] 35 Upstream flow meter
[0040] 37 Downstream flow meter
[0041] 39 Pig signal indicator
[0042] 40 Communication interface or network
[0043] 50 Computing device
[0044] 51 Computer readable media
[0045] 53 Memory
[0046] 55 Microprocessor
[0047] 60 Flow assurance module and method
[0048] 70 Valve change procedure
[0049] 71 Operator acknowledgement regarding current valve
states
[0050] 73 Valve state verification
[0051] 75 Request to change valve state
[0052] 77 Determine effect on product flow
[0053] 79 Operator acknowledgement to stop flow
[0054] 81 Modulate valve to requested new state
[0055] 83 Check differential pressure against predetermined
range
[0056] 85 Determine whether valve is in the requested new state
[0057] 87 Verify valve indicator matches new state
[0058] 90 Error procedure
[0059] 91 Stop all operations
[0060] 93 Indicate error state
[0061] 95 Error while modulating valve between current and
requested new state
[0062] 97 Reset valve to last known state
[0063] 99 Receive acknowledgement before re-start of operations
DETAILED DESCRIPTION
[0064] Referring to FIGS. 2 and 3, an embodiment of a valve
monitoring and flow assurance system and method for use with an
automated pig launcher 10 prevents blocking product flow of a
pipeline while changing valve states, including valve state changes
made without human intervention.
[0065] The launcher 10 includes a launcher barrel 11, a mainline
bypass 13 connected to a mainline 15, and a tee section 17. A
launch pin 18 holds a pig in its launch position and, once
launched, a pig signal indicator 39 indicates its passage into the
mainline 15. The valves--which includes the mainline bypass valve
21, kicker valve 25, and isolation valve 29--are each monitored by
a respective valve indicator 23, 27, 31 to determine whether the
valve 21, 25, 29 is correctly indicating a known state.
[0066] The launch pin 18, valve indicators 23, 27, 31, and pig
signal indicator 39 are in communication with a communication
interface 40--which can be connected to or part of a PLC network or
a mobile network--in communication with a computing device 50
having a flow assurance module 60 (see FIG. 3). The same is true of
pressure sensors or indicators 19, 33 and flow meters 35, 37.
[0067] Valve state data from the valve indicators 23, 27, 31,
differential pressure data from pressure indicators 19, 33, and
flow data from meters 35, 37 are passed through the interface 40
for processing by one or more microprocessors 55 of computing
device 50. The microprocessor 55, together with the
computer-readable media 51 and memory 53 of the computing device
50, implements a flow assurance module 60. The known number of pigs
loaded into the launcher barrel 11, along with data from the
retractable pin 18 and pig signal indicator 39, is used to
determine available pig status.
[0068] Referring to FIG. 4, the flow assurance module 60 includes a
valve change procedure 70 which executes various checks and
processes various requests to the valves. The valve change
procedure 70 begins with operator acknowledgement 71 regarding
current valve states. If a valve state is verified 73, and the same
holds true of the other valve states, then a request 75 can be sent
to change one or more of the valve states between this known state
and a second state. For example, the request 75 could be directed
toward modulating flow through the mainline bypass valve by
changing its state between a first partially opened state and a
second partially opened state, the flow through the mainline bypass
valve in the second state being greater than (or less than) that in
the first state.
[0069] The request 75 is then evaluated 77 to determine whether
changing the one or more valve states, given the current state of a
valve or valves, is desirable, thereby bringing the system into a
desired operating condition, or undesirable, such as one that could
stop or block product flow:
[0070] If MAINLINE=open, then KICKER=open or closed, ISOLATION=open
or closed, OR KICKER & ISOLATION=both open or both closed;
[0071] IF MAINLINE=closed, then KICKER.noteq.closed and
ISOLATION.noteq.closed;
[0072] IF KICKER=closed, or if ISOLATION=closed, then
MAINLINE.noteq.closed;
[0073] IF KICKER & ISOLATION=open, then MAINLINE=open or
closed.
[0074] If blocking is, or is likely, to occur, then operator
acknowledgement 79 is needed to change the valve state. If blocking
is not going to occur, then the request 75 is implemented 81 and
the one or more valves change states, with differential pressure 83
upstream and downstream of the mainline bypass valve being
monitored to determine whether it is within the proper upper and
lower bounds. Once the one or more valves have finished changing
states, the valves are again monitored 87 to determine whether the
valve indicators are matching a predicted state 85.
[0075] Referring to FIG. 5, if an error is received, an error
procedure 90 is started, all operations are stopped 91, including
valve changes. For example, if the error indicator 93 indicates the
error occurred while moving one of the valves between states 95,
and if the system is set-up to reset the valve to its previous
state, then the state change request 75 is reversed 97 to bring the
valve back to its previous state. Operator acknowledgement 99 of
the error correction is required before the re-start of
operations.
[0076] The embodiments described above provide illustrative
examples of the flow assurance system and method defined by the
following claims, including the range of equivalents to which the
claim language is entitled.
* * * * *